Burst Pressure Resistant Coalescer: Uncompromised Safety in Extreme High-Pressure Environments
Product Introduction
The Burst Pressure Resistant Coalescer is a groundbreaking solution engineered to deliver unmatched safety and reliability in high-pressure gas-liquid separation applications. Designed to operate under extreme pressures exceeding 200 bar (2900 psi), this coalescer combines robust structural integrity with advanced filtration technology to protect critical infrastructure in industries such as natural gas processing, aviation fuel purification, and hydraulic systems. Its patented burst-resistant design ensures zero leakage or catastrophic failure, even under sudden pressure surges or prolonged stress.
Key Features & Advantages
1. Extreme Burst Resistance
Rated Burst Pressure: Exceeds 250 bar (3625 psi), with safety margins validated through rigorous testing (ASME Section VIII compliance).
Reinforced Construction: Thick-walled stainless steel housing and proprietary composite materials prevent deformation or rupture.
2. Ultra-High Filtration Efficiency
Beta Ratio (β) > 50,000: Removes 99.999% of droplets ≥0.01 μm, including ultrafine aerosols and emulsions.
Multi-Layer Media: Combines nanofibers, hydrophobic coatings, and electrostatically charged layers for superior droplet capture.
3. Explosion-Proof Safety
Sealed Design: Hermetically sealed chambers eliminate the risk of fluid escape during pressure spikes.
Emergency Relief Valves: Integrated safety valves activate automatically if pressure exceeds safe thresholds.
4. Wide Application Flexibility
Fluid Compatibility: Safely handles natural gas, aviation fuel, hydraulic oil, sour gas, and emulsions.
Customizable Configurations: Single/multi-stage setups, specialized media coatings, and modular designs for tailored performance.
5. Longevity Under Stress
Working Principle
The Burst Pressure Resistant Coalescer operates through a three-step process:
1. Droplet Capture
Fluid (gas or liquid) enters the coalescer and flows through a bed of nanostructured fibers. Submicron droplets collide with fibers and aggregate into larger droplets due to electrostatic attraction and surface tension.
2. Separation
Gravity Separation: Enlarged droplets (>50 μm) settle at the bottom of the housing under gravity.
Centrifugal Separation: Optional cyclonic chambers accelerate droplet separation in high-flow applications.
3. Clean Fluid Discharge
Purified gas/liquid exits through the upper outlet, while collected liquid is drained via an automated valve or manual port.
Application Scenarios
1. High-Pressure Natural Gas Processing
Challenge: Remove water, hydrocarbon condensates, and corrosive acids (H₂S/CO₂) from raw gas at pressures up to 200 bar.
Solution: Ensures compliance with pipeline specifications (ISO 13678) and prevents hydrate formation in subsea pipelines.
2. Aviation Fuel Purification
Challenge: Meet aerospace standards (DEF STAN 91-91) by eliminating free water, surfactants, and particulates at pressures up to 50 bar.
Solution: Delivers <1 ppm free water and <0.3 μm particulate removal for safe turbine operation.
3. Hydraulic Systems
Challenge: Protect pumps and valves from water contamination and emulsions in high-pressure systems (up to 350 bar).
Solution: Breaks emulsions, removes water to <10 ppm, and extends oil life by 50% or more.
Technical Data
Parameter | Specification |
|---|
Model | BPRC-400 (Single-Stage), BPRC-600 (Multi-Stage) |
Fluid Type | Natural gas, aviation fuel, hydraulic oil, sour gas |
Operating Pressure | 20–250 bar (290–3625 psi) |
Temperature Range | -60°C to +200°C (-76°F to +392°F) |
Flow Rate | 200–200,000 Nm³/h (gas); 100–10,000 GPM (liquid) |
Beta Ratio (β) | β≥50,000 @ 0.01 μm; β≥100,000 @ 0.05 μm |
Removal Efficiency | 99.999% for 0.01–3 μm droplets; 99.9999% for >3 μm |
Pressure Drop | <0.03 bar @ rated flow |
Lifespan | 36–60 months (depending on contamination levels) |
Certifications | API 618, ISO 16889, ASTM D1655, ASME BPVC, PED 2014/68/EU |
Maintenance Guidelines
1. Routine Monitoring
Track differential pressure (ΔP) hourly during peak operations. Replace cartridges if ΔP exceeds 0.2 bar (initial ΔP: 0.02–0.05 bar).
Inspect housing and seals for cracks or leaks using ultrasonic testing.
2. Cartridge Replacement
3. Cleaning Procedures
Gas Service: Flush with dry nitrogen or compressed air to remove residual moisture.
Liquid Service: Soak in a mild detergent solution (e.g., isopropyl alcohol for aviation fuel), then rinse with deionized water.
4. Troubleshooting
Low Efficiency: Check for media fouling, incorrect installation, or exceeded β-ratio limits.
High ΔP: Clean or replace clogged pre-filters, or inspect for upstream equipment failure.
8 Frequently Asked Questions (FAQs)
1. What is the maximum pressure this coalescer can handle?
It is rated for 250 bar (3625 psi), with safety margins validated through burst testing.
2. How does it differ from standard high-pressure separators?
Unlike conventional separators, this coalescer combines burst-resistant materials with ultra-high filtration efficiency (β>50,000), ensuring both safety and precision.
3. Can it handle sour gas (H₂S/CO₂) at extreme pressures?
Yes. Materials like Hastelloy® C276 resist corrosion, ensuring reliable performance in H₂S-rich environments.
4. Is it suitable for offshore oil platforms?
Absolutely. Compact design, corrosion resistance, and explosion-proof features make it ideal for harsh marine environments.
5. What is the maximum flow rate for hydraulic systems?
Up to 10,000 GPM for multi-stage configurations, with pressure drops <0.05 bar.
6. Does it meet aerospace industry standards?
Yes. Certified to DEF STAN 91-91 and IATA requirements for jet fuel purity.
7. Can it be used for cryogenic LNG applications?
Specialized cryogenic models operate down to -162°C, ensuring efficient separation of water and hydrocarbons in liquefied natural gas systems.
8. What is the ROI of upgrading to a Burst Pressure Coalescer?
Customers typically achieve payback in 6–12 months through reduced maintenance, extended equipment life, and improved process efficiency.
Conclusion
The Burst Pressure Resistant Coalescer is the ultimate safeguard for industries where safety and precision are non-negotiable. Whether purifying natural gas, protecting jet engines, or optimizing hydraulic systems, its unmatched pressure tolerance, efficiency, and durability ensure peak performance even in the harshest environments. By investing in this technology, operators eliminate risks and maximize profitability in critical applications.
Need a custom solution? Contact our engineers today to design a coalescer tailored to your exact needs.
